Epoxy resin adhesive containing minor amounts of a polyurethane modifier



United States Patent 3,525,779 EPOXY RESIN ADHESIVE CONTAINING MINOR AMOUNTS OF A POLYURETHANE MODIFIER Jerry Marvin Hawkins, Lake Jackson, Tex., assignor to The Dow Chemical Company, Midland, Mich., a corporation of Delaware No Drawing. Continuation-impart of application Ser. No. 570,677, Aug. 4, 1966. This application Nov. 15, 1968, Ser. No. 776,251

Int. Cl. C08g 45/12 US. Cl. 260-830 8 Claims ABSTRACT OF THE DISCLOSURE A thermosettable resin composition comprising an epoxy resin, a modifier which is the adduct of a polyol and an isocyanate, said adduct having from \0-30% free isocyanate {-NCO) groups and a compound which is nonreactive with the epoxy resin and which contains either an -OH or --SH group in sufiicient quantity to react with the free isocyanate groups. This composition is particularly useful in adhesive formulations.

This application is a continuation-in-part of my copending application Ser. No. 570,677 filed Aug. 4, 1966, now abandoned.

This invention relates to improved thermosettable resin adhesive compositions. More particularly, the invention concerns epoxy resins containing a urethane-type modiher, which resins have significantly enhanced adhesion to metals.

It is desirable to provide epoxy resin formulations which are capable of rapid curing to form essentially non-tacky, flexible, thermoset materials having excellent adhesion to metals. Heretofore, efforts to achieve such results have included the utilization of flexibilizing curing agents such as the polyamides or polysulfides; or alternately, incorporating small percentages of elastomeric polymeric materials that are compatible but not reactive with the epoxy resin or hardener.

The flexibilizing curing agents must be employed in a relatively high ratio to the amount of epoxy resin. This alters the physical properties of the cured products so as to reduce such values as the tensile strength and partic ularly the shear strength. On the other hand, the elastomeric polymers are added in small quantities so that the flexibility of the cured product is enhanced without reducing the physical strength properties. The small quantity added, however, does not allow improvement beyond the increase in flexibility. For example, such properties as peel strength of epoxy adhesives for metals, or physical properties at reduced temperatures in the range of l00 F, are not improved.

According to our invention, rapid curing, essentially non-tacky, epoxy resin adhesive compositions having significantly enhanced adhesion to metals are prepared by addition to the epoxy resin, prior to curing thereof, the reaction product of 1) from about to about 40 parts per hundred parts of epoxy resin (phr.) of an adduct of a polyether polyol with an isocyanate wherein such adduct contains from 0 to up to about 30 percent by weight of free -NCO groups with (2) a compound containing at least one group selected from -0H and -SH which is present in sufiicient quantity to react with any free --NCO groups which may be present in the adduct, and which is non-reactive with the epoxy resin.

The polyether polyols which are employed in preparing the epoxy resin modifier (polyol-isocyanate adduct) as contemplated by the present invention, are those prepared by reacting a polyhydroxy compound having a Cal 3,525,779 Patented Aug. 25, 1970 ice functionality of from about 2 to about 6 such as ethylene glycol, propylene glycol, bntylene glycol, glycerine, trimethylol propane, pentaerythritol, sorbitol or a compound having reactive hydrogens such as ethylene di amine and aminoethyl ethanol amine; with an alkylene oxide such as ethylene oxide, propylene oxide, bntylene oxide and mixtures thereof. The molecular weight of the polyols may range from about 250 to about 5000 with 1285 to 3500 being the preferred range.

The isocyanates which are employed are those mono and polyfunctional organic isocyanates such as phenyl isocyanate, toluene diisocyanate, polyphenyl polymethyl isocyanate (PAPI), hexamethylene diisocyanate, p,p-diphenyl methane diisocyanate, fiuorinated monoisocyanate having the structure OHH H and the like. The invention contemplates the utilization of adducts of such polyether polyols and isocyanates having from 0 up to about 30 percent by weight of free NCO groups. When free NCO groups are present, a scavenger is reacted with such adduct in amounts sufficient to react with all of the free NCO groups. Ex emplary of such scavengers are the liquid alkanols (methanol, ethanol, propanol, isopropanol, butanol, lauryl alcohol, furfuryl alcohol and the like); substituted alkanols such an benzyl alcohol and the like; polyoxyalkylene glycols (diethylene glycol, triethylene glycol, tetraethylene glycol, dipropylene glycol, tripropylene glycol, tetrapropropylene glycol, dibutylene glycol, tributylene glycol, tetrabutylene glycol and the like); unsaturated alcohols such as allyl alcohol, methallyl alcohol, cinnamyl alcohol, l-butene-4-ol, l-pentene-S-ol, 1-hexene-6-ol, 2-butene-4-ol, 2-pentene-5-ol and the like; alkylene glycols (ethylene glycol, propylene glycol, bntylene glycol); alkyl ethers of glycols (methyl ether of ethylene glycol, ethyl ether of ethylene glycol, n-butyl ether of ethylene glycol, phenyl ether of ethylene glycol, pentane diol, methyl ether of diethylene glycol, ethyl ether of diethylene glycol, nbutyl ether of diethylene glycol, methyl ether of propylene glycol, methyl ether of dipropylene glycol, methyl ether of tripropylene glycol); hydroxy alkyl glycidyl ethers; benzyl alcohol; phenol; water; alkyl thiols (such as methane thiol, ethane thiol, propane thiol, butane thiol, etc.); alkyl dithiols (such as ethane dithiol, propane dithiol, butane dithiol); polythioalkyl dithiols wherein R is ethyl, propyl, butyl, etc. and n is an integer from 1 to about 5]; hydroxy or thiol containing esters of mono and di saturated aliphatic unsaturated aliphatic and aromatic carboxylic acids such as hydroxy ethyl acetate, hydroxy ethyl propionate, hydroxy ethyl butyrate, hydroxy ethyl acrylate, hydroxypropyl acrylate, hydroxy ethyl methacrylate, hydroxypropyl methacrylate, hydroxy ethyl benzoate, hydroxy propyl acetate, hydroxy propyl propionate, hydroxy propyl benzoate, etc. Any compound containing an active hydrogen atom capable of reacting with an NCO group would be acceptable providing such compound does not also contain a group which will react with the epoxide groups contained in the epoxy resin under conditions encountered during shipment and storage.

A compound containing a $H group is reactive, under certain conditions such as in the presence of a tertiary amine, with an epoxide group. However, under the conditions employed in the practice of the present invention, the scavengers containing a SH group will preferentially react with the free NCO groups in the polyol-iso- 4 cyanate adduct, with no detectable reaction with the epoxinteger having an average value of from about to ide groups of the epoxy resin. about 3;

Commercial epoxy resins of the type described under (C) L J L .Jb L

(A) (below) will contain a measurable concentration of 0 wherein R, R and R are independently hydrogen, an hydroxyl groups. These are secondary aliphatic hydroxyls alkyl or haloalkyl group having from about 1 to about 4 that are sluggishly reactive with isocyanate. Under the carbon atoms, and b, and C are integers, Sum of normal reaction conditions chosen, these hydroxyls remain which is an integer having an average value of from about entirely unreactive with the added isocyanate. However, 3 to about 40;

in some cases enough of these hydroxyls are available to react with the added isocyanate without the utilization of an additional scavenger. In order for the reaction to occur, higher reaction temperatures (l0()110 C.) and OCH2CHOHCH2 longer reaction times (about 2 hours) are required than I for the cases where a scavenger is employed.

The modifiers described herein are useful as adhesion X C CH2 OH CH promoting agents for use with a wide variety of the common epoxy resins and epoxy resin mixtures including the 1 glycidyl ethers of polyhydric henols, bisphenols, glycols, wherein X and X are as indicated in Formula B above. glycerine, polyoxyalkylene glycols, novolac resins and the (E) CHZX wherein n n and 11 are integers, the sum of which is an integer having an average value of from about 0 to about 4, X is a halogen and A is hydrogen or the group like, said epoxy resins being represented by the following formulae:

X X Cfi2 CHCH2O A- X X wherein A is selecfed from the group consisting of an wherein in and 21 are integers, the sum of which is an alkylene group havlng from 1 to 4 carbon atoms, integer from about 0 to about 4 and X is a halogen.

The epoxy resins represented by the Formulae A, B, C, g g D, E and F above may be referred to as epoxy resins of H the polyglycidyl ether type.

0 The preparation of the epoxy resins represented by and the l1ke, X is hydrogen or a halogen and n is an inte- Formulae A, B, C and D are well known and need not be ger having an average value of from about 0 to about 15; r discussed further.

0 The preparation of the epoxy resins represented by 0 0 OIFCIIZCH'CI'IZ )CIIaCfi- 0H2 0-CHzOfi- 0In CII2 E 3CII2-- X X1 LX X1 .in X X1 wherein X and X are independently selected from the Formulae E and F may be prepared by reacting glycerine group consisting of hydrogen and a halogen and n. is an orneopentyl glycol with an epihalohydrin in the presence of a Lewis acid and subsequently epoxidizing with an alkali metal hydroxide or carbonate in the conventional manner.

Mixtures of various epoxy resins including those described herein may also be employed in the practice of the present invention. It is or should be understood that it is Well known that different properties are obtained with different epoxy resins. This invention encompasses any epoxy resin of the glycidyl ether type containing modifiers as described herein wherein said modified epoxy resin provides for improved adhesion to metals as compared to the adhesion of the same epoxy resin without said modifier.

The modified epoxy resin compositions of this invention are preferably prepared by forming the modifier (the reaction product of a polyol-isocyanate adduct with a scavenger containing -OH or -SH groups) in situ in the epoxy resin although in some instances the modifier may be prepared and then blended with the epoxy resin. In the preferred method, the polyol-isocyanate adduct and the OH or -SH containing compound are added to the epoxy resin along with a suitable catalyst. The reaction is then generally conducted at a temperature of from about to C, at atmospheric or reduced pressures, for a time sufficient (about 30 minutes) to insure the complete disappearance of free --NCO groups (as determined by infrared analysis). Usually a period of about 30 minutes is required. Suitable catalysts are stannous octoate, dibutyl tin dilaurate, and the like. In some instances no catalyst is required if the reaction is conducted under elevated temperatures for extended periods of time, e.g. at about C. for periods of about 2 hours.

In addition, the polyol-isocyanate adduct of the present invention may be added to the epoxy resin in the form of a latex with subsequent removal of water prior to formulotion into an adhesive With the addition of fillers, etc. The particular advantage is the simplicity of blending latex with epoxy. Such a latex generally does not contain any free --NCO groups; therefore, the use of a scavenger so as to facilitate ease of handling. Suitable dilutents are butanediol diglycidyl ether, hydroxyethyl glycidyl ether, ethanediol diglycidyl ether, and phenyl glycidyl ether.

Further, the modified epoxy resin of this invention may be blended with most conventional fillers and curing agents. Suitable curing agents are dicyandiamide, n,n-di methylaminoethylmethacrylarnide, diethylaminopropylamine, aminoethyl piperazine, triethanol amine, aminated polyglycols such as aminated P250 (a polyoxypropylene glycol having an average molecular weight of about 250), Nadic Methyl Anhydride, diallylmelamine, and polyamides such as Versamid 140, 125, and among others and mixtures thereof. Suitable fillers are aluminum, silica, calcium carbonate, clay, organics, etc. (cellulose, wood, flour, etc.

Methods of preparing the compositions of the present invention and illustration of desirable and unexpected utility thereof, as adhesive coatings for metals, are presented in the following examples.

EXAMPLE I The following general procedures were used to prepare the modified epoxy resins of the present invention and to evaluate their effectiveness as adhesives.

(A) Preparation of the adduct of polyether polyol and isocyanate In each of a series of experiments, varying amounts of one of a series of polyether polyols were individually charged into a 500 ml. 3 neck reaction flask. Thereafter, the flask was purged with nitrogen, heated to a temperature of about 80 C. and varying amounts of one of a series of isocyanates added at a rate sufficient to maintain the reaction temperature between about 80 C. and 90 C. Following addition of the isocyanate, the mixture was allowed to digest at a temperature of about 80 C. with stirring for a period of about 3 hours.

(B) Modification of an epoxy resin would not be required. 40 In each of a serles of experlments, an epoxy resin was Diluents may also be added to the modified epoxy resin placed in a reactor and ag1tated while malntaimng the TABLE I.EFFECT 0F PoLYOLs Polyol Isocyanate Percent-- Modifier Amount Equiv. Amount, NCO in identification Type grns. wt. Type gms. adduct A P250 100 128 TDI 111 4.0 B 142.8 TDI 125 8.5 o 100 205 TDI 78.8 0.8 D 125 242 TDI 00 10.0 E 1,005 TDI 54 0.3 F 200 013 'lDI 33.0 4.0 G 200 013 'IDI 74.0 3.4 H 100 013 'IDI 180.4 30.0 I 200 013 TDI 74.0 0.5 I- 270 003 TDI 102 0.8 K 100 2,180 'IDI 0.35 3.0 L 100 2,180 TDI 30.5 0.8 M 100 1,330 TDI 15.5 3.7 N 100 1,330 TDI 33.5 0.8 o 150 1,570 TDI 48.7 0.1 P 2700 100 013 1-1MD1 35.8 11.2 Q Sorbi lbase 100 1,288 TDI 34.0 10.2

NOTE:

I Polyol Designation:

P250: Polyoxypropylene glycol having an average molecular weight of about 250. E300: Polyoxyethylene glycol having an average molecular weight of about 300.

P400: Polyoxypropyleno glycol having an average molecular weight of about 400. CP700: Glycerine initiated polyoxypropylene glycol having an average molecular weight of about 700. B2000: Polyoxybutylene glycol having an average molecular weight of about 2,000

CP2700: Glycerine initiated polyoxypropylene glycol having an average molecular Weight of about 2,700.

CP2700M: A mixture of glycerine initiated polyoxy propylene glycols havlng molecular weights of from about 200 to about 5,000, the average molecular weight of said mixture being about 2,700.

P4000: Polyoxypropylene glycol having an average molecular \velght of about 4,000.

CP4000: Glycerine initiated polyoxypropylene glycol having an average molecular weight of about 4,000.

CP5000: Glycerine initiated polyoxypropylene glycol having an average molecular weight of about 5,000.

Sorbitol based: Sorbitol reacted with propylene oxide to a molecular weight of about 750 followed by the addition of a mixture of 80 mole percent propylene oxide and 20 mole percent ethylene oxide to an equivalent Weight of about 1,288.

2 Isocyanate Designation:

TDI: Toluene diisocyanate. HMDI: Hexametliylene diisocyanate.

temperature of the reactor at about 85 C. To the reactor was then individually added a polyether polyol adduct prepared as in (A) above, along with varying amounts of types of hydroxy containing compounds (used to react with any free -NCO groups present in the adducts) and a small amount of stannous octoate as a catalyst. Each system was then placed under vacuum with stirring while under a temperature of about 85 C. until all of the isocyanate had been consumed as indicated by infrared analysis.

TABLE IL-EFFECI OF POLYOLS Adhesive Formulation, Modifier Properties Room Amount Room temp added Tetra- Approx. temp lap to epoxy ethylene Curing resin peel shear resin glycol, agent, Filler, viscosity, strength, strength, phr. (grams) phr. phr. polses lb./in. p.s.i.

None 10 20 O. 92 8 20 1. 98 8 20 2. 26 8 20 2. 36 8 20 2. 20 8 20 0. 92 8 20 1. 98 8 20 6. 85 8 2O 2. 20 8 20 2. 8 0. 83 1O 20 2. 20 10 20 0. 86 1O 20 2. 20 10 20 2. 11 8 15 1. 92 10 20 2. 10 10 1 No stannous octoate catalyst used.

(C) Evalution of the modified epoxy resin in an adhesive formulation Individual adhesive formulations were prepared having the following general ratio of formulation ingredients.

Phr. Modified epoxy resin 100 Hardener (dicyandiamide) 5-10 Cab-O-Sil (silica filler) 2.5-5 Al powder 70 Diluent 0-20 Table III illustrates the effect of various hydroxy containing compounds when used in the modified epoxy resins comprising the present invention. In all the formulations shown in Table III, the designated types and amounts of hydroxy-containing compounds were reacted with an adduct of the polyol and isocyanate, said adduct having been dispersed in the epoxy resin to the extent of 20 phr. of the adduct before the addition of the hydroxy containing compounds. The polyol was CP2700 or CP2700M as indicated. The isocyanate was toluene diisocyanate (TDI). The epoxy resin was the diglycidyl ether of bisphenol A having an epoxide equivalent Weight of 174 (DER-3 32). Thereafter, in all instances, to a portion of the thus modified epoxy resins was added and thoroughly mixed 8 phr. dicyandiamide and 5 phr. of silica filler (Cab-O-Sil). The formulations were then evaluated as adhesives as indicated.

TABLE III.EFFE CT OF DIFFERENT HYDROXY CONTAINING COMPOUNDS Properties Room Room temp. temp. lap MODIFIER peel shear Amount, Adduct, Epoxy, strength, strength, Hydroxy containing compound, type gms. Catalyst, gms; gms. gms. lb./in. p.s.i.

Ethanol 1 1. 07 Sn octoate (.025) 10 5s 4, 950 Tetraethylene glycol 1 96 0 10 50 83 5, 530 Diethylene glycol n-butyl ether 2. 86 Sn octoata (.020) 8 4O 63 Tripropylene glycol B 72 d0 8 40 51 Hydroxyethyl glycidyl ether 2 2. 75 Sn octoate (.025) 10 50 57 4, 700 Benzyl alcohol 10. 5 Sn octoate 05) 20 100 97 Allyl alcohol L... .9 do 20 100 5, 160 Methallyl alcohol 20 65 5, 600 Oinnamyl alcohol 45 90 4, 350 Hydroxy ethyl acrylate 1 30 150 40 5, 620

l Polyol was CP2700 as described following Table I 2 Polyol was CP27OOM as described following Table I. CP2700 type adduct was added to DER-331 (EEW=189) instead of DER-332.

cured 20 minutes at 200 C. and for the peel samples they were cured under a platen pressure of 16.5 lbs. per square inch at 200 C. for 20 minutes.

The preceding Table I specifically identifies a series of 70 polyether polyol-isocyanate adducts for subsequent use in combination with varying amounts of tetraethylene glycol.

The following Table II illustrates the combination of the modifiers of Table I with an epoxy resin and the eifec- 75 hesives.

TABLE IV.EFFEOT OF EPOXY RESINS Properties Modified Epoxy Resins Room Room temp. Epoxy resin Adduct Tetratemp. lap ethylene peel shear Percent glycol, strength, strength, Type l Gms. EEW 2 Polyol 3 Isocyanate -NCO Gms. gins. Diluent type 4 Phr. lb./in. p.s.i.

40 178 60 240 OP2700 'IDI 9. 8 36 8.8 Araldite RD2. 16 89 5,100 DER-32 25 174 DER-332 50 174 CP2700M TDI 9. 8 10 2. 3 None 83 5, 436

DE R-33l 50 189 CP2700M TDI 9.8 10 2.3 do 100 4,706

DER-337 45 240 CP2700M TDI 9. 8 10 2. 3 Araldite RD2 11 125 5, 196

EPON 834 45 255 CP2700M 'IDI 9. 8 10 2. 3 ...do 11 113 4, 490

i353 553:311116311313 3 1 25% lOPZYOOM Tm 2 None 95 DER'337 100 240 CP2700M TDI 9. 8 20 4. Araldite RD-2 115 5, 00 Ethyl-Acrylate lates 5 2. 3

DEN 439 50 205 DE R-337 50 240 CI2700M TDI 9. 8 20 None do 20 40 DE 12-332 174 IDGENG 150 138 CP2700 TDI 9. 1 6.25 None 78 1 Epoxy Resinsg DEN' lSS'.

([JI-laClI-CH2 C]H2Cfi-CH2 (|1HzCH-CH2 O 0 C I CH2 I: CID G L l. where n has an average value of about 1.6. DE N -13J: A semisolid novolac based epoxy resin having an EEW of about 205. DER Series and EPON:

O CH; OH CH l l I HzC-Cl1-CH;-O (I) O-OHr-CH-CHe O (J-1 L CH i OH;

DE R337: n has an average value of about 0.493. DE R-332: n has an average value of about 0.028. DE R-331: n has an average value of about 0.134. EPON 834: n has an average value of about 0.598. DER*667: n has an average value of about 11.5.

D GEN G: The Lewis acid catalyzed reaction product of neopentyl glycol with epichlorohydl'ln at a ratio of about 2 moles epichlorohydrin per mole of glycerine followed by expoxidation of the halohydrin with caustic 2 EEW: Epoxy equivalent W eight. 3 lolyol: See description following Table I. i Araldite RD 2: Butanediol diglycidyl other.

5 Ethylacrylate latex: An aorylate comprising 87% by weight ethylacrylate, 5% vinyl cyanide (acrylpnitrile), 5% hydroxy ethyl aorylate and 3% methacrylic acid. The water contained in the latex was removed by flashing after it had been thoroughly mlxed with the epoxy resin.

Table V illustrates the effect of various diluents which are useful in preparing the modified epoxy resins of the present invention. All formulations shown are formed from an adduct of a mixture of polyoxypropylcnc glycols made from propylene oxide initiated with glycerine, said mixture having an average molecular Weight of 2700 (CPI/00M), and toluene diisocyanate (TDI) wherein the adduct contains 9.8 percent of NCO. In each instance, the modifier (20 grams) was added to 100 grams of a diglycidyl ether of bisphenol A having an average n value of 0.493 and then 4.2 gins. tetraethylene glycol was used to react with the free NCO using a trace amount (approximately 0.05 gm.) of stannous octoate as a catalyst. To each formulation was then added 10 phr. of dicyandiamide and 5 phr. of silica filler and the designated types and amounts of diluent. The compositions were then evaluated as adhesives.

TABLE V.EFFECT OF DILUEN'IS 1 A mixture comprising 3 parts by weight of the diglycidyl ether of a polyoxypropylene glycol having an average molecular weight of about 400, said other having an EEW of about 320 and 1 part by weight of the diglycidyl ether of a polyoxypropyleue glycol having an average molecular weight of 250, said other having an EEW of about 190.

Table VI illustrates the cflects of using various isocyanates in preparing the modified epoxy resins of the 1 1 present invention. In each illustrated formulation the designated amounts and types of isocyanates were reacted With the specified amounts of a polyoxypropylene glycol made from propylene oxide initiated with glycerine to a molecular Weight of 2700 (CP2700) and then reacted with the specified amounts of tetraethylene glycol, in the presence of catalytic amounts of stannous octoate, while admixed with the specified amounts of a diglycidyl ether of bisphenol A having an epoxy equivalent weight of 174. Portions of the so-formed modified epoxy resins were then each admixed with 8 to 10 phr. dicyandiamide and phr. silica filler, prior to evaluation as adhesives.

12 adduct of 270 grams of polyether polyol CP270OM having an equivalent weight of 903, with 102 grams of toluene diisocyanate (wherein the adduct contained 9.8 percent of free --NCO) (2) adding 40 phr. of such adduct to a diglicidyl ether of bisphenol A having an epoxy equivalent weight of 174; and (3) adding tetraethyelne glycol in the presence of catalytic of stannous octoate to react all the isocyanate groups present. Thereafter, additional quantities of the unmodified epoxy resin were added to portions of the modified epoxy resin to give the desired modifier concentrations; along with 8 phr. of dicyandiamide, 5 phr. of silica filler, and 70 phr. of alumi- TABLE VI.-EFFECTS OF ISOCYANATES Modified Epoxy Resin Adhesive Properties Amount adduct Lap Epoxy in epoxy Peel shear Polyol; Percent resin, resin, TE G strength, strength, Gms. gms. 00 gms. phr. gms. ./in. p.s.i.

Isocyanate type TD 37. 4 100 8. 4 50 20 1. 9 84 5, 790 HM 35. 8 100 11. 4 53 4. 61 98 5 950 PI- 13. 7 100 0 50 30 None FI- 10. 0 32 0 5 None Mondur MR- 61. 5 100 9. 8 50 20 8 3. 8 5, 210 Multrathane M 60. 5 100 10. 3 60 4. 28 5, 920

diisocyanate.

2 Tetraethylene Glycol.

8 Dowanol DB (n-butyl ether of diethylene glycol) employed instead of 'IEG,

Table VII shows the effects of using various hardeners (curing agents) in preparing thermoset modified epoxy resins according to the present invention. In each formulation a modified epoxy resin was prepared by (a) forming an adduct of 200 grams of polyol CP27OO having an equivalent weight of 913 and 74.9 grams of toluene diisocyanate (wherein the adduct contained 8.4 percent free NCO); (b) mixing 0 to 20 phr. of the so-formed modifier with 10 to 100 grams of a diglycidyl ether of bisphenol A having an epoxy equivalent weight of 174, (c) reacting the adduct contained in the mixture with a stoichiometric amount of tetraethylene glycol. A portion of the thus modified epoxy resin was then admixed with 5 phr. of silica filler. Each mixture was then evaluated as an adhesive, after combining with the quantity of curing agent listed in Table VII.

TABLE VII.EFFECT OF CURING AGENT num powder filler. The mixtures were then evaluated as adhesives as indicated.

TABLE VIIL-EFFECT OF MODIFIER CONCENTRATION ON ADHESION Peel strength, lbs/in.

1 Based on that portion of the weight of the modifier contributed by the po1y0l1socyanate adduct only.

Table IX illustrates similar data obtained by utilization Epoxy resin Epoxy Peel Amount modifier, resin, strength, Curing agent, type phr. phr. gms lb .lin

Dieyandiamide 8 20 84 o 8 0 50 4 DER-331-diethy1ene triamine adduct wt.) 30 20 50 I 6 Do 30 O 50 4 4 Aminated P250 polyglycol 48. 5 20 50 I 50 Do 1 48. 5 0 50 4 6 Versamid 140 87 20 50 I 12 N ti t'ri'i hr b 1 87 0 50 46 a lo me y p enzy dimethyl amine 3 20 10 o 3 85 0 100 5 Triefhannlamina 12 20 10 l 46 Do 12 0 10 5 7 1 Polyoxypropyleneglycol diamine having an average moleeular weight of about 250. 2 Condensation product of polyamines and the dibasio acids obtained when certain unsaturated fatty acids are polymerized.

CH3 ll 0 4 Cure schedule=90 C. for 4 hrs. at 16.5 1b./in. platen pressure, and 80 C. for 10 hrs.

(no pressure).

5 Cure sehedule=230 F. C.) for 16 hrs. at 16.5 lb./in. 1 platen pressure.-

of a modified epoxy resin prepared by (1) utilizing an adduct of polyether polyol CP2700 with toluene diisocyanate which adduct contains 9.8 percent free NCO, (2) adding said adduct in the desired concentration to a mix- 13 ture of the epoxy resins DER-337, DER-332, and DEN- 438, and reacting the adduct contained in the epoxy resin mixture with tetraethylene glycol in the presence of staunous octoate. Thereafter a portion of each modified epoxy resin was individually admixed with 80 phr. aluminum powder filler, 6 phr. of silica filler, 0.3 phr. glycerine, 10 phr. dicyandiamide, and 1.5 phr. melamine.

The compositions were then evaluated as adhesives at the indicated test temperatures.

Adhesives were prepared by adding 10 phr. dicyandiamide to portions of the above modified epoxy resin and additional quantities of DER-332 required to prepare adhesives containing 20 and 15 phr. modifier (polyol- TDI adduct). The compositions containing 15 phr. and 20 phr. of the modifier were liquids as compared to the slight gel of the 30 phr. composition. Steel test specimens were prepared from each of the compositions with the following results.

TABLE IX.-EFFECT OF MODIFIER CONCENTRATION ON ADHESION Modifier Epoxy Resin Properties Epoxy Resin Peel Strength, lbs/in. Modifier, phr. Type Gms. 300 F. 250 F. 77 F. 77 F. F. -30 F. 67 F. 100 F. -200 F.

DER-337 60 2s 8 DER-332.- 25 1.5 12 42 83 62 62 68 51 44 n-332+2.3 phr. ethyl acrylate latex--. 20 i 0 0 116 61 16 1 Each of the above epoxy resin mixtures contained 20 phr. of the diluent butanediol diglycidyl ether.

EXAMPLE II Modifier conc. (phr.): Peel strength (lb./in.) 46 The modified epoxy resin compositions of this inven- 63 tion may be formed into films so as to be employed as 77 film adhesives. An example of such an application is as follows:

(1) A modifier was prepared by reacting 26.9 grams of hexamethylene diisocyanate with 100 grams of CP2700.

(2) 10 grams of the modifier was admixed with 50 grams of molten DER-661.

(3) 1.57 grams of tetraethylene glycol was added (no catalyst) to the mixture so as to react with the --NCO groups present therein.

(4) 2.5 grams of dicyandiamide was then blended into the mixture.

(5) A film was prepared by melting the composition between two Mi thick sheets of Tefion at 115 C. in a hot press.

(6) After cooling, the Tefion backing was removed and the thin sheet of adhesive material was cut into 1" strips. Even at room temperature the films were somewhat flexible.

(7) The 1" strips were employed as the adhesive for steel strips by placing the strip of adhesive between overlapping sections of two steel strips and curing in a hot press at 360 F. for min. The peel strength of this film adhesive was found to be 102 lbs./in.

When polyols that have a tertiary nitrogen group present such as those initiated with ethylene diamine and aminoethylethanol amine are employed, the catalytic effect which the tertiary nitrogen has toward crosslinking of the adduct must be inhibited. One method of inhibiting the catalytic effect is to convert the amine polyol to its hydrochloride salt by contacting the polyol with anhydrous HCl as in the following example.

EXAMPLE III In a suitable reaction flask was bubbled anhydrous HCl through 83.2 grams of a polyol prepared by reacting ethylene diamine with propylene oxide to a molecular weight of 3000 followed by the addition of ethylene oxide until a molecular weight of 3500 was obtained.

After infrared confirmed the conversion of the tertiary amine groups to their hydrochloride form, a modifier adduct was prepared by the dropwise addition of 30.9 grams of toluene diisocyanate at a temperature of about 80-85 C. followed by digestion for an additional 4 hours. The adduct contained 8.8% -NCO.

A modified epoxy resin was prepared by mixing 18 grams (30 phr.) of the adduct to 60 grams DER-332 (previously described) and reacting with 4 grams tetraethylene glycol. After 15 minutes at 90 C. a light gel formed. The NCO content had been reduced to practically zero.

The following example demonstrates the utility of a thiol as the scavenger and that the scavenger may be added to the polyol isocyanate adduct (modifier) prior to its addition to the epoxy resin and that a tertiary amine may be added so as to catalyze the reaction between the NCO and the scavenger.

EXAMPLE IV To a suitable reaction vessel was charged 25 grams of an adduct of CP2700 with toluene diisocyanate containing 9.8% --NCO, 50 grams methyl isobutyl ketone and 0.1 gram Dabco (triethylenediamine). The contents were heated to C. and 4.4 grams of butanethiol was added over a period of about 15 minutes and digested at 80 C. for 2 /2 hours and 15 hours at room temperature. The methyl isobutyl ketone solvent was then removed by stripping under vacuum. To 31.5 grams of DER-332 was added 6.3 grams of the above prepared modifier. The methyl isobutyl ketone was removed under vacuum and an adhesive prepared from a portion of the modified epoxy resin composition by admixing 2.5 grams (8 phr.) dicyandiamide and 1.5 grams (5 phr.) of silica filler. The adhesive was then tested and found to have a peel strength of 84 lbs./in. and a lap shear strength of 4020 p.s.i.

EXAMPLE V To a suitable reaction vessel was charged grams of DER-332 having an epoxide equivalent weight of 174. After heating to C., 67 grams of P102 urethane latex (44.9% solids) diluted with an equal volume of water to approximately 22.45% solids was added to the DER-332 in a dropwise manner while maintaining the temperature at 90 C. The water was then removed by heating at 90 C. and 35 mm. Hg for one hour.

Adhesive compositions were then prepared from the resultant modified epoxy resin at diiferent modifier levels by diluting portions of the above modified DER-3 32 with unmodified DER-332 and then blending into each sample Cab-O-Sil silica filler and dicyandiamide curing agent. The various samples were then evaluated as adhesives employing steel test specimens with the following results.

1 Urethane latex P102A is a high tensile strength, nonionic, urethane eo-polymer dispersed in water. having a fusion time of 10 minutes at 300 F., sold commercially by Wyandotte Chemicals Corp. The NCO content was 0%.

1 5 EXAMPLE VI A reaction vessel containing 50 grams of DER-331, 9.5 grams of an adduct of CP2700 and toluene diisocyanate (9.1% isocyanate) and 0.05 gram stannous octoate was heated at 130 C. for 1 hour. Infrared analysis of the resultant product revealed that no free NCO groups were present.

A test specimen was prepared from an adhesive comprising 120 parts by weight of the above modified epoxy resin, 8 phr. of dicyandiamide and 5 phr. silica filler. The test specimen had a peel strength of 86 lbs/in. after curing in a press at a platen pressure of 16.5 lbs. per square inch for 20 minutes at 200 C.

The novel modified epoxy resins described herein have particularly valuable utility as adhesives for metals such as stainless steel, low carbon high strength steel, copper and aluminum, among others. As specifically set forth herein, such utility extends over a wide range of temperatures, i.e. for temperatures ranging from about 200 F. to greater than 250 F. Further, such modified epoxy resins may be advantageously used as film type adhesives, castings, coatings, and laminates, as well as for use in preparing reinforced plastics, coatings, potting compounds, and the like.

What is claimed is:

1 A curable resin composition comprising essentially:

(A) an epoxy resin of the polyglycidyl ethers of polyhydric phenols and alcohols type, and

(B) a modifier, comprising the reaction product of (1) from about 5 to about 40 parts per hundred parts of said epoxy resin of an adduct of a polyether polyol and an organic isocyanate, said adduct having from up to about 30 percent by weight of free NCO groups, with (2) a scavenger compound which is non-reactive with said epoxy resin and which contains at least one active group from the class consisting of -OH and SH in sufiicient quantity to react with said free NCO groups.

2. The resin mixture of claim 1 wherein said polyether polyol has a molecular weight of from about 250 to about 5000.

3. A method of enhancing the adhesion of thermosettable epoxy resins of the polyglycidyl ethers of polyhydric phenols and alcohols type to metals comprising adding to said epoxy resins, prior to curing said resins to a thermoset condition, the reaction product of (1) from about to about 40 parts per hundred parts of said epoxy resin of an adduct of a polyether polyol with an isocyanate wherein said adduct contains from 0 up to about 30 percent by weight of free NCO with (2) a compound containing at least one group selected from OH and SH which is in sufficient quantity to react with any free NCO contained in said adduct and which is non-reactive with said epoxy resins.

4. The method of claim 3 wherein said polyether polyol has a molecular weight of from about 250 to 5000.

5. An adhesive in film form which comprises (A) a solid epoxy resin of the polyglycidyl ethers of polyhydric phenols and alcohols type,

(B) from about 5 to 40 parts per hundred parts of said epoxy resin of an adduct of a polyether polyol with an isocyanate, said adduct having from 0 to about 30 percent by weight of free NCO groups,

(C) a compound which is non-reactive with said epoxy resin and which contains at least one group selected from the class consisting of OH and SH in sufficient quantity to reduce the NCO content of (B) to substantially zero and (D) a curing amount of a latent curing agent.

6. The film adhesive of claim 5 wherein latent curing agent is dicyandiamide.

7. A curable resin composition comprising in admixture (A) an epoxy resin of the polyglycidyl ether of a hisphenol type containing secondary aliphatic hydroxyl groups, and

(B) from about 5 to about 40 parts per hundred parts of said epoxy resin of an adduct of a polyether polyol and an organic isocyanate, said adduct havifig from 0 up to about 30 percent by weight of free NCO groups, and wherein (A) and (B) have been heated at a temperature of at least about C. until the NCO content of said composition is substantially zero.

8. A curable resin composition comprising in admixture (A) an epoxy resin of the polyglycidyl ethers of polyhydric phenols and alcohols type, and

(B) from about 5 to about 40 parts per hundred parts of said epoxy resin of a urethane polymer wherein said urethane polymer is free from NCO groups and is admixed with (A) while in the form of a latex, and wherein the water content of said composition is substantially zero.

References Cited UNITED STATES PATENTS 3,148,167 9/1964 Keplinger 260-830 3,158,586 11/1964 Krause 260-830 3,23 8,273 3/1966 Hampson 260-830 3,239,580 3/1966 Pendleton 260-830 3,309,261 3/1967 Schiller 260-4330 3,324,974 6/1967 Champlin 260830 3,380,950 4/1968 Blomeyer 260-830 PAUL LIEBERMAN, Primary Examiner U.S. Cl. X.R. 

